3-coating
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Transcript of 3-coating
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Coating Technology forFlexible Packaging
Lee A. Ostness
Product Manager - Coating & Drying Systems
Flexible Packaging is widely used in todays world. It is used to package
a multitude of products such as: processed meat, processed cheese,
fresh red meat, bulk liquids, cereals, cake mix, coffee, medical device
films, snacks and many others. There are many different substrates and
coatings used to create these packages to produce the various levels of
barrier protection. see ch rt
SUBSTRATES COATINGS
PET 1 10 mil Primers 0.04 0.4 gsm
PE 1 8 mil Adhesives 3.25 6.5 gsm
Al Foil 20 60 PVDC 1.6 6.5 gsm
BOPP/OPP 0.4 2 mil Wash-coats 0.8 1.5 gsm
CPP 1 4 mil PVOH 0.5 gsm
Nylon 0.4 2 mil Lacquers 5.0 gsm
MetPET 1 10 mil Varnishes 0.02 0.04 gsm
Cellophane 0.8 1 mil Acrylic Polyurethanes 0.3 gsm
A typical package may be constructed of several layers of substrates and
coatings. Two typical constructions are illustrated below. The beveragepackage is constructed with PET/Printed/Primer coating/LDPE/Foil/LDPE heatseal).
The Retort Package is a different construction requiring two coatings,
PET/Printed/Adhesive coating/Foil/Primer coating/LDPE. The foil is a barrier
layer and may be substituted with Metalized PET, Nylon, or EVOH
depending on the amount or type of barrier required. see illustr tion
PET 12.6
(PRINT)
FOIL 6.3
LDPE 12.6
LDPE (Heat Seal) 25
PRIMER 0.04
Beverage Package
PET 12.6
(PRINT)
FOIL 6.3ADHESIVE 3.25 6.5
LDPE 25
PRIMER 0.04
Retort Package
PET 12.6
(PRINT)
FOIL 6.3
LDPE 12.6
LDPE (Heat Seal) 25
PRIMER 0.04
PET 12.6
(PRINT)
FOIL 6.3
LDPE 12.6
LDPE (Heat Seal) 25
PRIMER 0.04
Beverage Package
PET 12.6
(PRINT)
FOIL 6.3ADHESIVE 3.25 6.5
LDPE 25
PRIMER 0.04
Retort Package
PET 12.6
(PRINT)
FOIL 6.3ADHESIVE 3.25 6.5
LDPE 25
PRIMER 0.04
PET 12.6
(PRINT)
FOIL 6.3ADHESIVE 3.25 6.5
LDPE 25
PRIMER 0.04
Retort Package
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The constructions incorporate the use of solution coating(s) to enhance
either the barrier and/or the adhesion properties. The focus of this paper
is to discuss how these coatings are applied.
A solution coating is a liquid with solids dispersed in the liquid to assist
the wetting of the substrate it is applied to. The
liquid can be a combination of solvents or water
determined by its ability to maintain the dispersion
of the solids. The solution coating is applied to a
continuous web with a Coater and then passed
through a Dryer to remove the liquid leaving a thin
layer of solids on the substrate. The coater will beeither a gravure type or a smooth roll type. The
dryers are normally a roll support design or a
floatation design. The roll support dryer consist of
rolls supporting the web with opposing impingement nozzles drying the
web. The floatation dryer consist of nozzles on both sides of the web
creating a sign wave affect to float the web.
Coating heads have a variety of applications, strengths and weaknesses.
How do you objectively select the right coating head? There are 50 plus
coater configurations available to apply an infinite number of coating
solutions. To select the coater for your needs you first need to know
your coating and substrates properties, then match these properties with
the coaters abilities/limitations.
Coating Substrate Coater
% Solids Absorbency Speed Range
Viscosity Surface Tension Coat Weight Range
pH Tear Strength Solids Range
Shear Stability Smoothness Viscosity Range
Density Caliper Appearance
Solvent/Water Based Melt Point
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There are four main coater configurations used in the Flex Package
construction. The four types are Direct Gravure, Reverse Gravure, Offset
Gravure and Smooth Roll. The
gravure coaters utilize steel rolls
with patterns engraved into the
face of the roll. This pattern
determines how much coating is
carried to the web. The coating is
applied to the gravure, metered off the surface, leaving coating only in
the engraved pattern, then transferred to the web that is supported by
the rubber covered back-up roll. The smooth roll coater applies the
coating from an open pan, picking up the coating with a smooth steel rollpartially immersed into the pan, then the web is pressed against the steel
roll with the rubber covered back-up roll. The speed of the steel roll and
amount of pressure against the steel roll combine to control the amount
of coating applied to the web.
The gravure roll is a steel roll with a precise pattern engraved into the
surface of the roll. There are several gravure vendors, each with their
own names for these patterns. The picture shows one vendors patterns
and the names associated
with them. The patterns
are called from left to
right; Tri-Helical, Pyramid, Quadrangular, and Hexagonal. The amount
of coating in each cell (pattern) is measured and referred to as Billion
Cubic Microns (BCM). To select the correct gravure pattern for your
application, you need to reference a coat weight chart provided by most
gravure vendors. On this chart locate your coat weight under the percent
solids column that matches your formulation. Then follow the row to the
left and it determines the volume required to deliver the desired coating
to the substrate.
Direct
Gravure
Reverse
Gravure
Offset
Gravure
Smooth
Roll
Direct
Gravure
Reverse
Gravure
Offset
Gravure
Smooth
Roll
Direct
Gravure
Reverse
Gravure
Offset
Gravure
Smooth
Roll
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This chart is setup for the Direct Gravure method. The Reverse Gravure
method will need to add approximately 20% to the desired coat weight
and for Offset Gravure method add approximately 75%. This will be
explained as we discuss each type of coater and their operating
parameters.
The chart is only a starting point to get you close to your target. A large
amount of the time the gravure pattern will need to be adjusted to
achieve the correct coat weight due to the different coating and/or
substrate characteristics.
Direct Gravure Coater:
The Direct Gravure Coater consists of a rubber
covered back-up roll, a gravure roll, and a coating
applicator. The back-up roll is covered with a rubber
compound and is used to transport the web through
the coating process. The back-up roll is pressed
against the gravure roll creating a slight nip which pulls the coating out
of the gravure cells and deposits the coating onto the web. The gravure
roll is a steel roll with a pattern engraved into the face of the roll. These
cells are filled with the coating and doctored of the surface of the roll
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GSM
150%50% 100%
Gravure Speed
GSM
95% 100% 105%
Gravure Speed
leaving a precise amount of coating on the gravure roll. The roll then
transports the coating to the nip where it is transferred to the web. The
coating applicator is either an enclosed chamber with two doctor blades
or an open pan with a doctor blade assembly to remove the excess
coating. In the Direct Gravure mode the gravure roll and
the web are moving in the same direction at the point of
contact. The speed of the gravure roll is usually the same
as the web but it may be adjusted to 10% of the web
speed. The coat weight is determined by the gravure
volume and the coating solids.
Reverse Gravure Coater:
The Reverse Gravure Coater consists of the same
equipment as the Direct Gravure coater. In this
method the gravure roll runs in the opposite
direction to the web and varies in speed from 50%
to 150% of web speed. The most common
operating speed is 110% to 120%. The coat weight
in this mode when plotted will create a bell shaped curved by running the
gravure roll from 50 to 150% of web speed measuring the coat weight
every 10%. If the same gravure pattern from the Direct gravure is used
the highest coat weight will only be about 80% of the direct
gravure methods. The coat weight is determined by the
gravure pattern, the coating solids, and by the speed of the
gravure roll. This method will lay the coating down with a
smoother appearance because of the shearing action
created at the nip. The appearance created by the direct
gravure method is a rougher texture because at matched speeds and in
the same direction you are virtually printing the pattern onto the web.
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10% 60% 100%
Gravure Speed
GSM
Offset Gravure Coater:
The Offset GravureCoater consist of a steel back-up
roll, a rubber covered applicator roll, a gravure roll,
and a coating applicator. The back-up roll is chrome
plated steel roll used to transport the web through
the coating process and create the nip between the
web and the applicator roll. The Applicator roll is a
rubber covered roll used to transfer the coating from
the gravure roll to applicator roll, to the web. The gravure roll is a steel
roll with a pattern engraved into its surface. The coating applicator is
either an enclosed chamber with two doctor blades to an open pan with a
doctor blade assembly to remove the excess coating. In this method allthe rolls are turning in the same direction at the point of contact at each
nip. The back-up roll is operating at line speed, the applicator roll most
usually is operating at 98% of line speed (5%), and the gravure roll
operates at 25 to 35% of line speed. With this method
the coat weight curve when plotted would be a steady
incline then level off to a fairly straight plain. The curve
would be generated by varying the speed of the gravure
roll from 5% to 100 % in increments of 5%. The coat
weight usually levels off when the gravure roll reaches
about the 60% of line speed. The shearing action created by the
differential speeds and the two nip points generally apply a smooth
coating.
Smooth Roll Coater:
The Smooth RollCoaterconsist of a rubber covered back-
up roll, a steel chrome plated pick-up roll, sling guards
and a coating pan. The back-up roll is covered with a
rubber compound and is used to transport the web
through the coating process. The back-up roll is pressed
against the pick-up roll creating a slight nip. The pick-up roll is
immersed into the coating pan and transports the coating to the nip
between the web and the pick-up roll. The coating is applied to the web
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10% 100%
Pick-up Speed
GSM
at this nip point. The amount of coating applied is dependent on the
hydraulic forces at the coater nip created by the speed of the pick-up roll
and the nip force. The coating pan is filled with a solution coating and in
most cases it has an overflow weir so the coating may be recirculated.
The rubber compound selected has to consider several operational
conditions. The parameters consist of the durometer, surface tension,
resilience, tear resistance. The durometer needs to be based on the
speed of the machine line and the viscosity of the coating. With this
method the coat weight increases with higher speed and higher viscosity.
The surface tension is selected based on the compound of the rubber.
This method requires the rubber to repel the coating, so only the web will
be coated. The resilience and tear strength are required due to the highforces and different web widths. The coat weight is determined by the nip
width and the pick-up roll speed and the curve will be a line
with a slow incline and then when the hydraulic forces
overcome the nip the line transitions into a steep incline.
The wider the nip the lower on the graph the curve is
generated.
The gravure coater requires the rubber
rolls to be undercut slightly narrower than
the web width whereas in the smooth roll
method the rubber rolls are full width.
When the coating is transferred to the
web or applicator roll from the gravure cells it only needs to be
transferred at the width of the web. If the rubber is not undercut the
coating would form a flooded nip outside the area of the web and
gradually move into the web area, creating a hydraulic force that would
increase the coat weight to unacceptable levels in these areas. If the
rubber was undercut, the area outside the width of the web would
continue to travel around and back into the coating applicator. The
smooth roll coater requires a full width rubber roll to create the flooded
nip. If the nip was not flooded across the entire web, some areas would
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have either too little coating or none at all. This flooded nip also requires
sling guards at the end of the rolls to catch and return into the pan any of
the slinging coating.
A nip is required between the coating rolls in all of the methods listed
above. What is a nip? A nip is the amount of contact that is generated
between the rolls when they are pressed together. The softer the rubber
durometer, the wider the nip will be with the same pressure. As the
pressure increases the nip width increases. How do you measure the nip
width? There are several methods available using
carbon nip paper, aluminum foil, liquid coating and
piece of paper, a computerized nip blanket. What allthese methods have in common is you must place
something between the two rolls before you close
them together.
In review, the coat weight control of each coater as depicted in the charts
show that the only coater that cannot adjust coat weight is the Direct
Gravure (shown s forw rd gr vure in the illustr tion).
GSM
150%5 0% 1 00 %
Gravure Speed
Reverse
Gravure
GSM
95 % 10 0% 1 05%
Gravure Speed
Forward
Gravure
10% 60% 100%
Gravure Speed
GSM
Offset
Gravure
10% 100%
Pick-up Speed
GSM
Smooth
Transfer
GSM
150%5 0% 1 00 %
Gravure Speed
Reverse
Gravure
GSM
150%5 0% 1 00 %
Gravure Speed
Reverse
Gravure
150%5 0% 1 00 %
Gravure Speed
Reverse
Gravure
GSM
95 % 10 0% 1 05%
Gravure Speed
Forward
Gravure
10% 60% 100%
Gravure Speed
GSM
Offset
Gravure
10% 100%
Pick-up Speed
GSM
Smooth
Transfer
GSM
95 % 10 0% 1 05%
Gravure Speed
Forward
Gravure
10% 60% 100%
Gravure Speed
GSM
Offset
Gravure
10% 60% 100%
Gravure Speed
GSM
Offset
Gravure
10% 100%
Pick-up Speed
GSM
Smooth
Transfer
10% 100%
Pick-up Speed
GSM
Smooth
Transfer
The smooth roll coater can control coat weight until the hydraulic force
over comes the coater nip and then the coat weight climbs dramatically.
The Gravure coaters offer excellent coat weight control and are stable
through out all line speeds but require an undercut rubber roll for each
web width. A sleeve system may be used in the rubber roll location. The
sleeve system allows the rubber undercut sleeve to be changed in less
than 15 minutes. This system still requires a sleeve for each web width.
The smooth roll coater offers coat weight control but needs adjustment
going from low to high line speeds. This is referred to as unstable, as
IMPRESSION
PAPER
TORQUE SHAFT
SHOULD BE
LEVELED
RUBBER
COVERED
ROLL
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the line speed increases so does the amount of coating supplied. The
result is much of the coated web during speed-up and slow down is
waste. The advantage to the smooth roll coater is it only requires one
rubber roll for all web widths.
GSM
Line Speed
Gravure
Smooth Roll
GSM
Line Speed
Gravure
Smooth Roll
The Direct Gravure coater is used primarily on substrates that are fragile,
like metalized PET or printed webs. If the roll applying the coating to
these two examples were operated in the reverse direction or at a
differential speed, then that roll could damage the print layer or pick off
the foil. Operating the roll in the forward direction with matched speeds
will apply the coating without damage. The smooth roll coater can adjust
coat weights and apply coatings without damage to the layers. The limit
on this coater is the flooded nip. This application works well on films or
coated papers, BUT on open face paper the coat weight cannot be
controlled. Passing the open faced paper through the flooded nip will
saturate the web and apply excessive coating.
Take all the parameters from this paper and create a chart, now you can
select the correct coater for your process.
Coater Selection
Direct
Gravure
Reverse
Gravure
Offset
Gravure
Smooth
Roll
Ability to Adjust Coat Weight No Yes Yes Yes
Ability to Coat Paper Yes Yes Yes No
Ability to Coat Film Yes Yes Yes Yes
Stable at all Line Speeds Yes Yes Yes No
Requires Under Cut Rubber Roll Yes Yes Yes No
Ability to Coat Printed Film Yes No Yes Yes
Ability to Coat Foil Yes No Yes Yes
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2006 PLACE
Conference
September 17-21
Cincinnati, Ohio
Coating TechnologyforFlexible Packaging
Presented by:
Lee A. Ostness
Product ManagerCoating & Drying Systems
Black Clawson Converting Machinery
Typical Products
ProductProcessed Meat
Processed Cheese
Fresh Red Meat
Bulk Liquids
Cereal/Cake Mix
Medical Devices Films
Coffee
Fresh Produce
Snacks
Package TypePouches, Vacuum Packages
Pouches, Wraps
Barrier, Shrink Bags
Pouches, Bag in Box
Inner Liners
Pouches, Thermal Formed
Brick Packs, Pouches
Breathable Bags
Bags
Flex-Pack Components
Substrates
PET 1-10 mil
PE 1-8 mil
Al foil 20-60
BOPP/OPP 0.4-2 mil
CPP 1-4 mil
Nylon 0.4-2 mil
METPET 1-10 mil
Cellophane 0.8-1 mil
Coatings
Primers 0.04-0.4 gsm
Adhesives 3.25-6.5 gsm
PVDC 1.6-6.5 gsm
Wash-coats 0.8-1.5 gsm
PVOH 0.5 gsm
Lacquer 5.0 gsm
Acrylic Polyurethane 0.3 gsm
Varnish 0.02 0.04 gsm
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Typical Product Structures
PET 12.6
(PRINT)
FOIL 6.3
LDPE 12.6
LDPE (Heat Seal) 25
PRIMER 0.04
Beverage Package
PET 12.6
(PRINT)
FOIL 6.3
ADHESIVE 3.25 6.5
LDPE 25
PRIMER 0.04
Retort Package
Note: The foil is a barrier layer and may be substituted with METPET, Nylon, or EVOH
depending on the amount or type of barrier layer needed.
COATER/DRYER
Coater
Smooth roll
Backing Roll not Undercut
Pan Fed
Direct Gravure
Backing Roll Undercut
Sleeve
Pan Fed
Enclosed Applicator
Dryer
Air Floatation Nozzles
Roll Support
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FLEX-PACK COATERS
Direct
Gravure
Reverse
Gravure
Offset
Gravure
Smooth
Roll
Methodology of Application
Gravure Coater Smooth Roll Coater
Gravure Engraved Patterns
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Volume
BCMBillion Cubic Microns
The formula is based onink technology. Many of
today's coatings are of
an unique composition.Use this formula for a
better understanding ofhow the cell volumes are
achieved. Coat weights
may vary when different
coatings are applied withthe same cell volume.
formula from Consolidated Engravers
DIRECT GRAVURE: is 80 % of what the chart displays
REVERSE GRAVURE: is generally 80% of Direct GravureDIFFERENTIAL OFFSET GRAVURE: is generally 25% of Direct Gravure
CHARTSREFERENCE DFROM:
PAMARCO,INC.
2 00 0 . 00 08 2 . 6 0 .2 1 0 . 26 0 .3 2 0 . 47 0 .7 0 2 00 0 . 00 12 5 . 7 0 .2 2 0 . 32 0 .4 8 0 .7 1 1 .0 5 1 .3 1 1 20 0 .0 02 2 1 8. 0 0 .6 4 0 .9 5 1 .4 0 2 .0 7 3 .0 7 3 .8 0 ARCINDUSTRIES, INC.
1 80 0 . 00 09 3 . 2 0 .2 3 0 . 29 0 .3 6 0 . 53 0 .7 9 1 90 0 . 00 15 7 . 5 0 .2 7 0 . 40 0 .6 0 0 .8 9 1 .3 1 1 .6 3 1 10 0 .0 02 5 2 0. 3 0 .7 3 1 .0 8 1 .6 0 2 .3 7 3 .5 1 4 .3 5 AMERICANENGRAVINGAND MACHINECO.
1 65 0 . 00 10 3 . 4 0 .2 6 0 . 32 0 .4 0 0 . 59 0 .8 8 1 80 0 . 00 18 9 . 4 0 .3 3 0 . 48 0 .7 2 1 .0 7 1 .5 8 1 .9 6 9 5 0 .0 03 2 2 6. 2 0 .9 4 1 .3 9 2 .0 5 3 .0 3 4 .4 9 5 .5 7 MODERNENGRAV INGAND MACHINE CO.
1 50 0 . 00 20 7 . 5 0 .5 1 0 . 64 0 .8 0 1 . 18 1 .7 5 1 65 0 . 00 22 1 0 .9 0 .3 0 0 . 49 0 .8 0 1 .3 0 1 .9 3 2 .3 9 9 0 0 .0 03 5 2 8. 8 1 .0 3 1 .5 2 2 .2 5 3 .3 3 4 .9 3 6 .1 1
1 42 0 . 00 22 8 . 2 0 .5 6 0 . 70 0 .8 8 1 . 30 1 .9 2 1 50 0 . 00 25 1 3 .3 0 .4 6 0 . 68 1 .0 0 1 .4 8 2 .1 9 2 .7 2 8 4 0 .0 03 9 3 2. 3 1 .1 4 1 .6 9 2 .5 0 3 .7 0 5 .4 8 6 .7 9
1 32 0 . 00 25 9 . 7 0 .6 4 0 . 80 1 .0 0 1 . 48 2 .1 9 1 40 0 . 00 28 1 5 .0 0 .5 1 0 . 76 1 .1 2 1 .6 6 2 .4 5 3 .0 5 7 9 0 .0 04 0 3 2. 7 1 .1 8 1 .7 5 2 .5 8 3 .8 1 5 .6 4 6 .9 9
1 20 0 . 00 30 1 1 .0 0 .7 7 0 . 96 1 .2 0 1 . 78 2 .6 3 1 30 0 . 00 30 1 6 .0 0 .5 5 0 . 8 1 1 . 20 1 .7 8 2 .6 3 3 .2 6 7 2 0 .0 04 5 3 6. 8 1 .3 2 1 .9 5 2 .8 8 4 .2 6 6 .3 0 7 .8 1
1 16 0 . 00 32 1 1 .9 0 .8 1 1 . 02 1 .2 8 1 . 89 2 .8 0 1 20 0 . 00 32 1 7 .2 0 .5 9 0 . 8 7 1 . 28 1 .8 9 2 .8 0 3 .4 8 6 4 0 .0 05 1 4 1. 8 1 .5 0 2 .2 2 3 .2 8 4 .8 5 7 .1 8 8 .8 9
1 08 0 . 00 33 1 2 .2 0 .8 5 1 . 06 1 .3 2 1 . 95 2 .8 9 1 10 0 . 00 39 2 1 .4 0 .7 1 1 . 0 5 1 . 56 2 .3 1 3 .4 2 4 .2 4 5 9 0 .0 05 5 4 5. 0 1 .6 1 2 .3 9 3 .5 3 5 .2 2 7 .7 3 9 .5 7
1 00 0 . 00 35 1 3 .9 1 .0 3 1 . 20 1 .4 0 2 . 07 3 .0 7 9 6 0 . 00 44 2 6 .3 0 .8 0 1 . 1 9 1 . 76 2 .6 1 3 .8 5 4 .7 9 5 4 0 .0 06 0 4 9. 0 1 .7 6 2 .6 0 3 .8 5 5 .7 0 8 .4 4 1 0. 46
9 0 0 . 00 38 1 6 .0 0 .9 8 1 . 22 1 .5 2 2 . 25 3 .3 3 8 5 0 . 00 49 3 0 .0 0 .9 0 1 . 32 1 .9 6 2 .9 0 4 .2 9 5 .3 3 5 0 0 .0 06 5 5 3. 3 1 .9 1 2 .8 3 4 .1 8 6 .1 8 9 .1 5 1 1. 34
8 0 0 . 00 40 1 7 .3 1 .0 2 1 . 28 1 .6 0 2 . 37 3 .5 0 7 5 0 . 00 54 3 2 .0 0 .9 8 1 . 4 6 2 . 16 3 .2 0 4 .7 3 5 .8 8 4 5 0 .0 07 3 5 9. 6 2 .1 4 3 .1 7 4 .6 8 6 .9 2 1 0. 25 1 2. 70
7 0 0 . 00 45 1 8 .0 1 .1 5 1 . 44 1 .8 0 2 . 66 3 .9 4 6 5 0 . 00 60 3 5 .4 1 .1 0 1 . 6 2 2 . 40 3 .5 5 5 .2 6 6 .5 3 4 2 0 .0 07 5 6 1. 5 2 .1 9 3 .2 5 4 .8 0 7 .1 0 1 0. 52 1 3. 04
6 5 0 . 00 50 2 0 .4 1 .2 8 1 . 60 2 .0 0 2 . 96 4 .3 8 5 5 0 . 00 65 4 0 .4 1 .1 9 1 . 7 6 2 . 60 3 .8 5 5 .6 9 7 .0 7 3 6 0 .0 09 0 7 3. 3 2 .6 4 3 .9 1 5 .7 8 8 .5 5 1 2. 66 1 5. 68
6 0 0 . 00 58 2 4 .4 1 .4 9 1 . 86 2 .3 2 3 . 43 5 .0 8 4 5 0 . 00 68 4 4 .5 1 .2 4 1 . 8 4 2 . 72 4 .0 3 5 .9 6 7 .4 0 3 5 0 .0 09 3 7 6. 0 2 .8 0 4 .0 9 5 .9 8 8 .7 4 1 3. 10 1 6. 23
5 5 0 . 00 62 2 6 .6 1 .5 8 1 . 98 2 .4 8 3 . 67 5 .4 3 3 5 0 . 00 70 4 6 .6 1 .2 8 1 . 8 9 2 . 80 4 .1 4 6 .1 3 7 .6 2 3 3 0 .0 09 6 7 8. 2 2 .8 1 4 .1 6 6 .1 5 9 .1 0 1 3. 48 1 6. 70
5 0 0 . 00 76 3 3 .7 1 .9 4 2 . 42 3 .0 2 4 . 47 6 .6 1 3 0 0 . 00 90 5 8 .7 1 .6 4 2 . 4 3 3 . 60 5 .3 3 7 .8 8 9 .7 9 2 8 0 .0 11 0 9 0. 0 3 .2 2 4 .7 7 7 .0 5 1 0. 43 1 5. 45 1 9. 15
4 5 0 . 0 09 0 4 1. 0 2 . 3 0 2 . 8 8 3 . 60 5 .3 3 7 . 8 8 2 5 0 . 0 12 0 8 1 .0 2 . 19 3 . 25 4 . 80 7 . 10 1 0 .5 1 1 3 .0 6 2 6 0 .0 1 30 1 0 6. 5 3 . 81 5 .6 3 8 . 33 1 2 .3 2 1 8 .2 5 2 2 .6 14 0 0 . 0 10 4 4 8. 0 2 . 6 7 3 . 3 3 4 . 16 6 .1 5 9 . 1 1 1 6 0 . 0 17 0 11 7 .0 3 . 1 1 4 . 6 0 6 . 80 1 0 .0 6 1 4 .8 9 1 6 .5 0 2 4 0 .0 1 40 1 1 5. 0 4 . 09 6 .0 5 8 . 95 1 3 .2 4 1 9 .6 2 2 4 .3 1
DIRECT FORWARD GRAVURE
0 .0 00 8 2. 6 0 . 17 0 . 21 0 . 26 0 . 38 0 . 56 0 .0 01 2 5. 7 0 . 18 0 . 26 0 . 38 0 .5 7 0 .8 4 1 .0 5 0 .0 01 2 5 .7 0 .2 0 0 . 30 0 .4 4 0 . 6 5 0 .9 7 1 .2 1 0 .0 02 2 1 8. 0 0 . 51 0 .7 6 1 .1 2 1 .6 6 2 .4 6 3 .0 4
0 .0 00 9 3. 2 0 . 19 0 . 23 0 . 29 0 . 42 0 . 63 0 .0 01 5 7. 5 0 . 22 0 . 32 0 . 48 0 .7 1 1 .0 5 1 .3 0 0 .0 01 5 7 .5 0 .2 5 0 . 37 0 .5 5 0 . 8 2 1 .2 1 1 .5 0 0 .0 02 5 2 0. 3 0 . 58 0 .8 6 1 .2 8 1 .9 0 2 .8 1 3 .4 8
0 .0 01 0 3. 4 0 . 20 0 . 26 0 . 32 0 . 47 0 . 70 0 .0 01 8 9. 4 0 . 26 0 . 39 0 . 58 0 .8 6 1 .2 6 1 .5 7 0 .0 01 8 9 .4 0 .3 0 0 . 45 0 .6 6 0 . 9 8 1 .4 5 1 .8 0 0 .0 03 2 2 6. 2 0 . 75 1 .1 1 1 .6 4 2 .4 2 3 .5 9 4 .4 6
0 .0 02 0 7. 5 0 . 41 0 . 51 0 . 64 0 . 94 1 . 40 0 .0 02 2 10 .9 0 . 24 0 . 39 0 . 64 1 .0 4 1 .5 4 1 .9 1 0 .0 02 2 1 0. 9 0 . 28 0 .4 5 0 . 74 1 .2 0 1 .7 8 2 .2 0 0 .0 03 5 2 8. 8 0 . 82 1 .2 2 1 .8 0 2 .6 6 3 .9 4 4 .8 9
0 .0 02 2 8. 2 0 . 45 0 . 56 0 . 70 1 . 04 1 . 54 0 .0 02 5 13 .3 0 . 37 0 . 54 0 . 80 1 .1 8 1 .7 5 2 .1 8 0 .0 02 5 1 3. 3 0 . 42 0 .6 2 0 . 92 1 .3 6 2 .0 1 2 .5 0 0 .0 03 9 3 2. 3 0 . 91 1 .3 5 2 .0 0 2 .9 6 4 .3 8 5 .4 3
0 .0 02 5 9. 7 0 . 51 0 . 64 0 . 80 1 . 18 1 . 75 0 .0 02 8 15 .0 0 . 41 0 . 60 0 . 90 1 .3 3 1 .9 6 2 .4 4 0 .0 02 8 1 5. 0 0 . 47 0 .7 0 1 . 03 1 .5 3 2 .2 5 2 .8 1 0 .0 04 0 3 2. 7 0 . 95 1 .4 0 2 .0 6 3 .0 5 4 .5 1 5 .5 9
0 .0 03 0 11 .0 0 . 61 0 . 77 0 . 96 1 . 42 2 . 10 0 .0 03 0 16 .0 0 . 44 0 . 6 5 0 .9 6 1 . 42 2 .1 0 2 .6 1 0 .0 03 0 1 6. 0 0 . 5 0 0 .7 4 1 . 10 1 .6 4 2 .4 2 3 .0 0 0 .0 04 5 3 6. 8 1 .0 5 1 . 56 2 .3 0 3 .4 1 5 .0 4 6 .2 5
0 .0 03 2 11 .9 0 . 65 0 . 82 1 . 02 1 . 51 2 . 24 0 .0 03 2 17 .2 0 . 47 0 . 6 9 1 .0 2 1 . 51 2 .2 4 2 .7 8 0 .0 03 2 1 7. 2 0 . 5 4 0 .8 0 1 . 18 1 .7 4 2 .5 8 3 .2 0 0 .0 05 1 4 1. 8 1 .2 0 1 . 77 2 .6 2 3 .8 8 5 .7 4 7 .1 1
0 .0 03 3 12 .2 0 . 68 0 . 85 1 . 06 1 . 56 2 . 31 0 .0 03 9 21 .4 0 . 57 0 . 8 4 1 .2 5 1 . 85 2 .7 4 3 .3 9 0 .0 03 9 2 1. 4 0 . 6 5 0 .9 7 1 . 44 2 .1 3 3 .1 5 3 .9 0 0 .0 05 5 4 5. 0 1 .2 9 1 . 91 2 .8 2 4 .1 8 6 .1 8 7 .6 6
0 .0 03 5 13 .9 0 . 82 0 . 96 1 . 12 1 . 66 2 . 46 0 .0 04 4 26 .3 0 . 64 0 . 9 5 1 .4 1 2 . 09 3 .0 8 3 .8 3 0 .0 04 4 2 6. 3 0 . 7 4 1 .0 9 1 . 62 2 .4 0 3 .5 4 4 .4 1 0 .0 06 0 4 9. 0 1 .4 1 2 . 08 3 .0 8 4 .5 6 6 .7 5 8 .3 7
0 .0 03 8 16 .0 0 . 78 0 . 98 1 . 22 1 . 80 2 . 66 0 .0 04 9 30 .0 0 . 72 1 . 0 6 1 .5 7 2 . 32 3 .4 3 4 .2 6 0 .0 04 9 3 0. 0 0 . 8 2 1 .2 2 1 . 80 2 .6 7 3 .9 5 4 .9 0 0 .0 06 5 5 3. 3 1 .5 3 2 . 26 3 .3 4 4 .9 4 7 .3 2 9 .0 7
0 .0 04 0 17 .3 0 . 82 1 . 02 1 . 28 1 . 90 2 . 80 0 .0 05 4 32 .0 0 . 79 1 . 1 7 1 .7 3 2 . 56 3 .7 8 4 .7 0 0 .0 05 4 3 2. 0 0 . 9 1 1 .3 4 1 . 99 2 .9 4 4 .3 5 5 .4 1 0 .0 07 3 5 9. 6 1 .7 1 2 . 53 3 .7 4 5 .5 4 8 .2 0 1 0. 16
0 .0 04 5 18 .0 0 . 92 1 . 15 1 . 44 2 . 13 3 . 15 0 .0 06 0 35 .4 0 . 88 1 . 3 0 1 .9 2 2 . 84 4 .2 1 5 .2 2 0 .0 06 0 3 5. 4 1 . 0 1 1 .4 9 2 . 21 3 .2 7 4 .8 4 6 .0 1 0 .0 07 5 6 1. 5 1 .7 6 2 . 60 3 .8 4 5 .6 8 8 .4 2 1 0. 43
0 .0 05 0 20 .4 1 . 02 1 . 28 1 . 60 2 . 37 3 . 50 0 .0 06 5 40 .4 0 . 95 1 . 4 0 2 .0 8 3 . 08 4 .5 5 5 .6 6 0 .0 06 5 4 0. 4 1 . 0 9 1 .6 2 2 . 39 3 .5 4 5 .2 3 6 .5 0 0 .0 09 0 7 3. 3 2 .1 1 3 . 13 4 .6 2 6 .8 4 1 0. 13 1 2. 54
0 .0 05 8 24 .4 1 . 19 1 . 49 1 . 86 2 . 74 4 . 06 0 .0 06 8 44 .5 0 . 99 1 . 4 7 2 .1 8 3 . 22 4 .7 7 5 .9 2 0 .0 06 8 4 4. 5 1 . 1 4 1 .6 9 2 . 50 3 .7 1 5 .4 8 6 .8 1 0 .0 09 3 7 6. 0 2 .2 4 3 . 27 4 .7 8 6 .9 9 1 0. 48 1 2. 98
0 .0 06 2 26 .6 1 . 26 1 . 58 1 . 98 2 . 94 4 . 34 0 .0 07 0 46 .6 1 . 02 1 . 5 1 2 .2 4 3 . 31 4 .9 0 6 .1 0 0 .0 07 0 4 6. 6 1 . 1 8 1 .7 4 2 . 58 3 .8 1 5 .6 4 7 .0 1 0 .0 09 6 7 8. 2 2 .2 5 3 . 33 4 .9 2 7 .2 8 1 0. 78 1 3. 36
0 .0 07 6 33 .7 1 . 55 1 . 94 2 . 42 3 . 58 5 . 29 0 .0 09 0 58 .7 1 . 31 1 . 9 5 2 .8 8 4 . 26 6 .3 0 7 .8 3 0 .0 09 0 5 8. 7 1 . 5 1 2 .2 4 3 . 31 4 .9 0 7 .2 5 9 .0 1 0 .0 11 0 9 0. 0 2 .5 8 3 . 81 5 .6 4 8 .3 4 1 2. 36 1 5. 32
0 .0 09 0 41 .0 1 . 8 4 2 .3 0 2 . 88 4 .2 6 6 . 30 0 .0 12 0 81 .0 1 . 76 2 .6 0 3 . 84 5 .6 8 8 .4 1 1 0. 45 0 .0 12 0 8 1. 0 2 .0 2 2 . 99 4 .4 2 6 .5 3 9 .6 7 1 2. 02 0 .0 13 0 1 06 .5 3 .0 5 4 . 51 6 .6 6 9 . 86 1 4 .6 0 18 .0 90 .0 10 4 4 8. 0 2 . 13 2 .6 6 3 . 33 4 .9 2 7 . 29 0 .0 17 0 11 7. 0 2 .4 9 3 . 68 5 .4 4 8 .0 5 1 1. 91 1 3. 20 0 .0 17 0 1 17 .0 2 .8 6 4 .2 3 6 .2 6 9 .2 6 1 3. 70 1 5. 18 0 .0 14 0 1 15 .0 3 .2 7 4 . 84 7 .1 6 1 0. 59 1 5 .7 0 1 9. 45
DIRECT REVERSEGRA VURE
0 .0 00 8 2. 6 0 . 14 0 . 17 0 . 20 0 . 30 0 . 45 0 .0 01 2 5. 7 0 . 14 0 . 21 0 . 31 0 .4 5 0 .6 7 0 .8 4 0 .0 01 2 5 .7 0 .1 6 0 . 24 0 .3 5 0 . 5 2 0 .7 7 0 .9 6 0 .0 02 2 1 8. 0 0 . 41 0 .6 1 0 .9 0 1 .3 2 1 .9 6 2 .4 3
0 .0 00 9 3. 2 0 . 15 0 . 19 0 . 23 0 . 34 0 . 51 0 .0 01 5 7. 5 0 . 17 0 . 26 0 . 38 0 .5 7 0 .8 4 1 .0 4 0 .0 01 5 7 .5 0 .2 0 0 . 30 0 .4 4 0 . 6 6 0 .9 6 1 .2 0 0 .0 02 5 2 0. 3 0 . 47 0 .6 9 1 .0 2 1 .5 2 2 .2 5 2 .7 8
0 .0 01 0 3. 4 0 . 16 0 . 20 0 . 26 0 . 38 0 . 56 0 .0 01 8 9. 4 0 . 21 0 . 31 0 . 46 0 .6 8 1 .0 1 1 .2 5 0 .0 01 8 9 .4 0 .2 4 0 . 36 0 .5 3 0 . 7 9 1 .1 6 1 .4 4 0 .0 03 2 2 6. 2 0 . 60 0 .8 9 1 .3 1 1 .9 4 2 .8 7 3 .5 6
0 .0 02 0 7. 5 0 . 33 0 . 41 0 . 51 0 . 76 1 . 12 0 .0 02 2 10 .9 0 . 19 0 . 32 0 . 51 0 .8 3 1 .2 4 1 .5 3 0 .0 02 2 1 0. 9 0 . 22 0 .3 6 0 . 59 0 .9 6 1 .4 2 1 .7 6 0 .0 03 5 2 8. 8 0 . 66 0 .9 7 1 .4 4 2 .1 3 3 .1 6 3 .9 1
0 .0 02 2 8. 2 0 . 36 0 . 45 0 . 56 0 . 83 1 . 23 0 .0 02 5 13 .3 0 . 29 0 . 43 0 . 64 0 .9 5 1 .4 0 1 .7 4 0 .0 02 5 1 3. 3 0 . 34 0 .5 0 0 . 74 1 .0 9 1 .6 1 2 .0 0 0 .0 03 9 3 2. 3 0 . 73 1 .0 8 1 .6 0 2 .3 7 3 .5 1 4 .3 5
0 .0 02 5 9. 7 0 . 41 0 . 51 0 . 64 0 . 95 1 . 40 0 .0 02 8 15 .0 0 . 33 0 . 48 0 . 72 1 .0 6 1 .5 7 1 .9 5 0 .0 02 8 1 5. 0 0 . 38 0 .5 6 0 . 82 1 .2 2 1 .8 0 2 .2 4 0 .0 04 0 3 2. 7 0 . 76 1 .1 2 1 .6 5 2 .4 4 3 .6 1 4 .4 7
0 .0 03 0 11 .0 0 . 49 0 . 61 0 . 77 1 . 14 1 . 68 0 .0 03 0 16 .0 0 . 35 0 . 5 2 0 .7 7 1 . 14 1 .6 8 2 .0 9 0 .0 03 0 1 6. 0 0 . 4 0 0 .6 0 0 . 88 1 .3 1 1 .9 4 2 .4 0 0 .0 04 5 3 6. 8 0 .8 4 1 . 25 1 .8 4 2 .7 3 4 .0 3 5 .0 0
0 .0 03 2 11 .9 0 . 52 0 . 65 0 . 82 1 . 21 1 . 79 0 .0 03 2 17 .2 0 . 38 0 . 5 5 0 .8 2 1 . 21 1 .7 9 2 .2 3 0 .0 03 2 1 7. 2 0 . 4 3 0 .6 4 0 . 94 1 .3 9 2 .0 6 2 .5 6 0 .0 05 1 4 1. 8 0 .9 6 1 . 42 2 .1 0 3 .1 0 4 .6 0 5 .6 9
0 .0 03 3 12 .2 0 . 54 0 . 68 0 . 84 1 . 25 1 . 85 0 .0 03 9 21 .4 0 . 46 0 . 6 7 1 .0 0 1 . 48 2 .1 9 2 .7 1 0 .0 03 9 2 1. 4 0 . 5 2 0 .7 8 1 . 15 1 .7 0 2 .5 2 3 .1 2 0 .0 05 5 4 5. 0 1 .0 3 1 . 53 2 .2 6 3 .3 4 4 .9 5 6 .1 2
0 .0 03 5 13 .9 0 . 66 0 . 77 0 . 90 1 . 32 1 . 96 0 .0 04 4 26 .3 0 . 51 0 . 7 6 1 .1 3 1 . 67 2 .4 6 3 .0 7 0 .0 04 4 2 6. 3 0 . 5 9 0 .8 7 1 . 30 1 .9 2 2 .8 3 3 .5 3 0 .0 06 0 4 9. 0 1 .1 2 1 . 66 2 .4 6 3 .6 5 5 .4 0 6 .6 9
0 .0 03 8 16 .0 0 . 63 0 . 78 0 . 97 1 . 44 2 . 13 0 .0 04 9 30 .0 0 . 57 0 . 8 5 1 .2 5 1 . 86 2 .7 5 3 .4 1 0 .0 04 9 3 0. 0 0 . 6 6 0 .9 7 1 . 44 2 .1 3 3 .1 6 3 .9 2 0 .0 06 5 5 3. 3 1 .2 2 1 . 81 2 .6 8 3 .9 6 5 .8 6 7 .2 6
0 .0 04 0 17 .3 0 . 66 0 . 82 1 . 02 1 . 52 2 . 24 0 .0 05 4 32 .0 0 . 63 0 . 9 3 1 .3 8 2 . 05 3 .0 3 3 .7 6 0 .0 05 4 3 2. 0 0 . 7 2 1 .0 7 1 . 59 2 .3 6 3 .4 8 4 .3 3 0 .0 07 3 5 9. 6 1 .3 7 2 . 03 3 .0 0 4 .4 3 6 .5 6 8 .1 3
0 .0 04 5 18 .0 0 . 74 0 . 92 1 . 15 1 . 70 2 . 52 0 .0 06 0 35 .4 0 . 70 1 . 0 4 1 .5 4 2 . 27 3 .3 7 4 .1 8 0 .0 06 0 3 5. 4 0 . 8 1 1 .1 9 1 . 77 2 .6 1 3 .8 7 4 .8 1 0 .0 07 5 6 1. 5 1 .4 0 2 . 08 3 .0 7 4 .5 4 6 .7 3 8 .3 5
0 .0 05 0 20 .4 0 . 82 1 . 02 1 . 28 1 . 89 2 . 80 0 .0 06 5 40 .4 0 . 76 1 . 1 2 1 .6 6 2 . 46 3 .6 4 4 .5 2 0 .0 06 5 4 0. 4 0 . 8 7 1 .2 9 1 . 91 2 .8 3 4 .1 9 5 .2 0 0 .0 09 0 7 3. 3 1 .6 9 2 . 50 3 .7 0 5 .4 7 8 .1 0 1 0. 04
0 .0 05 8 24 .4 0 . 95 1 . 19 1 . 48 2 . 20 3 . 25 0 .0 06 8 44 .5 0 . 79 1 . 1 7 1 .7 4 2 . 58 3 .8 1 4 .7 4 0 .0 06 8 4 4. 5 0 . 9 1 1 .3 5 2 . 00 2 .9 7 4 .3 9 5 .4 5 0 .0 09 3 7 6. 0 1 .7 9 2 . 62 3 .8 3 5 .5 9 8 .3 8 1 0. 39
0 .0 06 2 26 .6 1 . 01 1 . 27 1 . 59 2 . 35 3 . 48 0 .0 07 0 46 .6 0 . 82 1 . 2 1 1 .7 9 2 . 65 3 .9 2 4 .8 8 0 .0 07 0 4 6. 6 0 . 9 4 1 .3 9 2 . 06 3 .0 5 4 .5 1 5 .6 1 0 .0 09 6 7 8. 2 1 .8 0 2 . 66 3 .9 4 5 .8 2 8 .6 3 1 0. 69
0 .0 07 6 33 .7 1 . 24 1 . 55 1 . 93 2 . 86 4 . 23 0 .0 09 0 58 .7 1 . 05 1 . 5 6 2 .3 0 3 . 41 5 .0 4 6 .2 7 0 .0 09 0 5 8. 7 1 . 2 1 1 .7 9 2 . 65 3 .9 2 5 .8 0 7 .2 1 0 .0 11 0 9 0. 0 2 .0 6 3 . 05 4 .5 1 6 .6 8 9 .8 9 1 2. 26
0 .0 09 0 41 .0 1 . 47 1 . 84 2 . 30 3 . 41 5 . 04 0 .0 12 0 81 .0 1 . 40 2 . 0 8 3 .0 7 4 . 54 6 .7 3 8 .3 6 0 .0 12 0 8 1. 0 1 . 6 1 2 .3 9 3 . 53 5 .2 3 7 .7 4 9 .6 1 0 .0 13 0 1 06 .5 2 .4 4 3 . 60 5 .3 3 7 .8 8 1 1. 68 1 4. 470 .0 10 4 4 8. 0 1 . 71 2 .1 3 2 . 66 3 .9 4 5 . 83 0 .0 17 0 11 7. 0 1 .9 9 2 . 94 4 .3 5 6 .4 4 9 .5 3 1 0. 56 0 .0 17 0 1 17 .0 2 .2 9 3 .3 8 5 .0 0 7 .4 0 1 0. 96 1 2. 14 0 .0 14 0 1 15 .0 2 .6 2 3 . 87 5 .7 3 8 . 47 1 2 .5 6 1 5. 56
0 .0 00 8 2. 6 0 . 06 0 . 07 0 . 08 0 . 12 0 . 18 0 .0 01 2 5. 7 0 . 06 0 . 09 0 . 13 0 .1 9 0 .2 8 0 .3 5 0 .0 01 2 5 .7 0 .0 7 0 . 10 0 .1 5 0 . 2 2 0 .3 2 0 .4 0 0 .0 02 2 1 8. 0 0 . 17 0 .2 5 0 .3 7 0 .5 5 0 .8 1 1 .0 0
0 .0 00 9 3. 2 0 . 06 0 . 08 0 . 10 0 . 14 0 . 21 0 .0 01 5 7. 5 0 . 07 0 . 11 0 . 16 0 .2 3 0 .3 5 0 .4 3 0 .0 01 5 7 .5 0 .0 8 0 . 12 0 .1 8 0 . 2 7 0 .4 0 0 .4 9 0 .0 02 5 2 0. 3 0 . 19 0 .2 9 0 .4 2 0 .6 3 0 .9 3 1 .1 5
0 .0 01 0 3. 4 0 . 07 0 . 08 0 . 11 0 . 16 0 . 23 0 .0 01 8 9. 4 0 . 09 0 . 13 0 . 19 0 .2 8 0 .4 2 0 .5 2 0 .0 01 8 9 .4 0 .1 0 0 . 15 0 .2 2 0 . 3 2 0 .4 8 0 .6 0 0 .0 03 2 2 6. 2 0 . 25 0 .3 7 0 .5 4 0 .8 0 1 .1 9 1 .4 7
0 .0 02 0 7. 5 0 . 14 0 . 17 0 . 21 0 . 31 0 . 46 0 .0 02 2 10 .9 0 . 08 0 . 13 0 . 21 0 .3 4 0 .5 1 0 .6 3 0 .0 02 2 1 0. 9 0 . 09 0 .1 5 0 . 24 0 .3 9 0 .5 9 0 .7 3 0 .0 03 5 2 8. 8 0 . 27 0 .4 0 0 .5 9 0 .8 8 1 .3 0 1 .6 1
0 .0 02 2 8. 2 0 . 15 0 . 18 0 . 23 0 . 34 0 . 51 0 .0 02 5 13 .3 0 . 12 0 . 18 0 . 26 0 .3 9 0 .5 8 0 .7 2 0 .0 02 5 1 3. 3 0 . 14 0 .2 1 0 . 30 0 .4 5 0 .6 6 0 .8 3 0 .0 03 9 3 2. 3 0 . 30 0 .4 5 0 .6 6 0 .9 8 1 .4 5 1 .7 9
0 .0 02 5 9. 7 0 . 17 0 . 21 0 . 26 0 . 39 0 . 58 0 .0 02 8 15 .0 0 . 13 0 . 20 0 . 30 0 .4 4 0 .6 5 0 .8 1 0 .0 02 8 1 5. 0 0 . 15 0 .2 3 0 . 34 0 .5 0 0 .7 4 0 .9 3 0 .0 04 0 3 2. 7 0 . 31 0 .4 6 0 .6 8 1 .0 1 1 .4 9 1 .8 5
0 .0 03 0 11 .0 0 . 20 0 . 25 0 . 32 0 . 47 0 . 69 0 .0 03 0 16 .0 0 . 14 0 . 2 1 0 .3 2 0 . 47 0 .6 9 0 .8 6 0 .0 03 0 1 6. 0 0 . 1 7 0 .2 5 0 . 36 0 .5 4 0 .8 0 0 .9 9 0 .0 04 5 3 6. 8 0 .3 5 0 . 51 0 .7 6 1 .1 2 1 .6 6 2 .0 6
0 .0 03 2 11 .9 0 . 21 0 . 27 0 . 34 0 . 50 0 . 74 0 .0 03 2 17 .2 0 . 15 0 . 2 3 0 .3 4 0 . 50 0 .7 4 0 .9 2 0 .0 03 2 1 7. 2 0 . 1 8 0 .2 6 0 . 39 0 .5 7 0 .8 5 1 .0 6 0 .0 05 1 4 1. 8 0 .4 0 0 . 59 0 .8 7 1 .2 8 1 .9 0 2 .3 5
0 .0 03 3 12 .2 0 . 22 0 . 28 0 . 35 0 . 51 0 . 76 0 .0 03 9 21 .4 0 . 19 0 . 2 8 0 .4 1 0 . 61 0 .9 0 1 .1 2 0 .0 03 9 2 1. 4 0 . 2 2 0 .3 2 0 . 47 0 .7 0 1 .0 4 1 .2 9 0 .0 05 5 4 5. 0 0 .4 3 0 . 63 0 .9 3 1 .3 8 2 .0 4 2 .5 3
0 .0 03 5 13 .9 0 . 27 0 . 32 0 . 37 0 . 55 0 . 81 0 .0 04 4 26 .3 0 . 21 0 . 3 1 0 .4 6 0 . 69 1 .0 2 1 .2 6 0 .0 04 4 2 6. 3 0 . 2 4 0 .3 6 0 . 53 0 .7 9 1 .1 7 1 .4 5 0 .0 06 0 4 9. 0 0 .4 6 0 . 69 1 .0 2 1 .5 0 2 .2 3 2 .7 6
0 .0 03 8 16 .0 0 . 26 0 . 32 0 . 40 0 . 59 0 . 88 0 .0 04 9 30 .0 0 . 24 0 . 3 5 0 .5 2 0 . 77 1 .1 3 1 .4 1 0 .0 04 9 3 0. 0 0 . 2 7 0 .4 0 0 . 60 0 .8 8 1 .3 0 1 .6 2 0 .0 06 5 5 3. 3 0 .5 0 0 . 75 1 .1 0 1 .6 3 2 .4 2 2 .9 9
0 .0 04 0 17 .3 0 . 27 0 . 34 0 . 42 0 . 63 0 . 92 0 .0 05 4 32 .0 0 . 26 0 . 3 8 0 .5 7 0 . 84 1 .2 5 1 .5 5 0 .0 05 4 3 2. 0 0 . 3 0 0 .4 4 0 . 66 0 .9 7 1 .4 4 1 .7 9 0 .0 07 3 5 9. 6 0 .5 7 0 . 84 1 .2 4 1 .8 3 2 .7 1 3 .3 5
0 .0 04 5 18 .0 0 . 30 0 . 38 0 . 48 0 . 70 1 . 04 0 .0 06 0 35 .4 0 . 29 0 . 4 3 0 .6 3 0 . 94 1 .3 9 1 .7 2 0 .0 06 0 3 5. 4 0 . 3 3 0 .4 9 0 . 73 1 .0 8 1 .6 0 1 .9 8 0 .0 07 5 6 1. 5 0 .5 8 0 . 86 1 .2 7 1 .8 7 2 .7 8 3 .4 4
0 .0 05 0 20 .4 0 . 34 0 . 42 0 . 53 0 . 78 1 . 16 0 .0 06 5 40 .4 0 . 31 0 . 4 6 0 .6 9 1 . 02 1 .5 0 1 .8 7 0 .0 06 5 4 0. 4 0 . 3 6 0 .5 3 0 . 79 1 .1 7 1 .7 3 2 .1 5 0 .0 09 0 7 3. 3 0 .7 0 1 . 03 1 .5 3 2 .2 6 3 .3 4 4 .1 4
0 .0 05 8 24 .4 0 . 39 0 . 49 0 . 61 0 . 91 1 . 34 0 .0 06 8 44 .5 0 . 33 0 . 4 8 0 .7 2 1 . 06 1 .5 7 1 .9 5 0 .0 06 8 4 4. 5 0 . 3 8 0 .5 6 0 . 83 1 .2 2 1 .8 1 2 .2 5 0 .0 09 3 7 6. 0 0 .7 4 1 . 08 1 .5 8 2 .3 1 3 .4 6 4 .2 8
0 .0 06 2 26 .6 0 . 42 0 . 52 0 . 65 0 . 97 1 . 43 0 .0 07 0 46 .6 0 . 34 0 . 5 0 0 .7 4 1 . 09 1 .6 2 2 .0 1 0 .0 07 0 4 6. 6 0 . 3 9 0 .5 7 0 . 85 1 .2 6 1 .8 6 2 .3 1 0 .0 09 6 7 8. 2 0 .7 4 1 . 10 1 .6 2 2 .4 0 3 .5 6 4 .4 1
0 .0 07 6 33 .7 0 . 51 0 . 64 0 . 80 1 . 18 1 . 75 0 .0 09 0 58 .7 0 . 43 0 . 6 4 0 .9 5 1 . 41 2 .0 8 2 .5 8 0 .0 09 0 5 8. 7 0 . 5 0 0 .7 4 1 . 09 1 .6 2 2 .3 9 2 .9 7 0 .0 11 0 9 0. 0 0 .8 5 1 . 26 1 .8 6 2 .7 5 4 .0 8 5 .0 6
0 .0 09 0 41 .0 0 . 61 0 . 76 0 . 95 1 . 41 2 . 08 0 .0 12 0 81 .0 0 . 58 0 . 8 6 1 .2 7 1 . 87 2 .7 7 3 .4 5 0 .0 12 0 8 1. 0 0 . 6 7 0 .9 9 1 . 46 2 .1 6 3 .1 9 3 .9 7 0 .0 13 0 1 06 .5 1 .0 1 1 . 49 2 .2 0 3 .2 5 4 .8 2 5 .9 7
0 .0 10 4 48 .0 0 . 7 0 0 .8 8 1 . 10 1 .6 2 2 . 41 0 .0 17 0 11 7. 0 0 .8 2 1 . 21 1 . 80 2 .6 6 3 .9 3 4 .3 6 0 .0 17 0 1 17 .0 0 .9 4 1 . 40 2 .0 6 3 .0 5 4 .5 2 5 .0 1 0 .0 14 0 1 15 .0 1 .0 8 1 . 60 2 .3 6 3 . 50 5 .1 8 6 . 42
TRI-HELICAL CELLCHART #11
PYRAMIDCELLCHART #12 QUADRANGULAR CELLCHART #13 QUADRANGULAR CHANNELED CELLCHART #14 TRI-HELICAL CELLCHART #15
QUADRANGULAR CHANNELED CELLCHART#6
5%
SOLIDS
15%
SOLIDS
25%
SOLIDS
35%
SOLIDS
35%
SOLIDS
45%
SOLIDS
50%
SOLIDSVOLUME
5%
SOLIDS
15%
SOLIDS
25%
SOLIDS
45%
SOLIDS
50%
SOLIDS CELL DEPTH
5%
SOLIDS
15%
SOLIDS
25%
SOLIDS
35%
SOLIDS
50%
SOLIDS CELL DEPTH VOLUME
15%
SOLIDS
25%
SOLIDS
35%
SOLIDS
45%
SOLIDS
CELL
DEPTH VOLUME
5%
SOLIDS
15%
SOLIDS
25%
SOLIDS
35%
SOLIDS
45%
SOLIDS
CELL
DEPTH VOLUME
5%
SOLIDS
35%
SOLIDS
45%
SOLIDS
50%
SOLIDS
OFFSET GRAVURE OFFSET GRAVURE OFFSET GRAVURE OFFSET GRAVURE
VOLUME 5%
SOLIDS
15%
SOLIDS
25%
SOLIDS
45%
SOLIDS
50%
SOLIDS CELL DEPTH
5%
SOLIDS
15%
SOLIDS
25%
SOLIDS
35%
SOLIDS
50%
SOLIDS CELL DEPTH VOLUME
15%
SOLIDS
25%
SOLIDS
35%
SOLIDS
45%
SOLIDS
CELL
DEPTH VOLUME
5%
SOLIDS
15%
SOLIDS
25%
SOLIDS
35%
SOLIDS
45%
SOLIDS
CELL
DEPTH VOLUME
5%
SOLIDS
PYRAMIDCELLCHART #8 QUADRANGULAR CELLCHART #9 QUADRANGULAR CHANNELED CELLCHART#10
35%
SOLIDS
45%
SOLIDSCELL DEPTH
5%
SOLIDS
15%
SOLIDS
25%
SOLIDS
35%
SOLIDS
50%
SOLIDS
DIRECT REVERSE GRAVURE DIRECT REVERSE GRAVURE DIRECT REVERSE GRAVURE
VOLUME 5%
SOLIDS
15%
SOLIDS
25%
SOLIDS
45%
SOLIDS
50%
SOLIDS
50%
SOLIDS CELL DEPTH VOLUME
15%
SOLIDS
25%
SOLIDS
35%
SOLIDS
45%
SOLIDS
CELL
DEPTH VOLUME
5%
SOLIDS
15%
SOLIDS
25%
SOLIDS
35%
SOLIDS
45%
SOLIDS
CELL
DEPTH VOLUME
5%
SOLIDS
TRI-HELICAL CELLCHART #7
6.CHOOSETHEROLL FROM ANY VENDORCHART THAT
MATCHES THE VOLUME AND CELL TYPE.
D IR EC T F OR WA RD G RA VU RE D IR EC T F OR WA RD G RA VU RE D IR EC T F OR WA RD G RA VU RE
PYRAMIDCELLCHART #4 QUADRANGULAR CELLCHART #5
2.DETERMINETYPEOF GRAVURECOATER
3.DETERMINETYPEOF GRAVURECELL
4.FIND THE DESIREDCOATWEIGHT IN THECHART
5.TRACETHATROLL OVERTO THE VOLUMEINTHESAMECHART
45%
SOLIDS
50%
SOLIDS
NOTE: THISISFOR CHROME PLATED GRAVURE ROLLS ONLY!
1.DETERMINESOLIDS
50%
SOLIDS NUMBER CELL DEPTH VOLUME
15%
SOLIDS
25%
SOLIDS
35%
SOLIDS
45%
SOLIDSNUMBER
CELL
DEPTH VOLUME
5%
SOLIDS
15%
SOLIDS
25%
SOLIDS
35%
SOLIDS
45%
SOLIDSNUMBER
CELL
DEPTH VOLUME
5%
SOLIDS
ENGRAVINGCOATING CHARTWEIGHT INPOUNDSDRYSOLIDS PERREAM - 432,000SQUARE INCHES
WEIGHT OF MATERIAL 8 LBS. PERGALLONINSOLUTION
PYRAMIDCELLCHART #1 QUADRANGULAR CELLCHART #2 TRI-HELICAL CELLCHART#3
-
7/23/2019 3-coating
14/17
DIRECT GRAVURE
BACKING; LINESPEED
Undercut Required
BACKING/GRAVURE = 3/8 NIP
GRAVURE; 90% to 110% LINESPEED
USUALLY REQUIRES POST SMOOTHING
REVERSE GRAVURE
BACKING; LINESPEED
Undercut required
BACKING/GRAVURE = 3/8 NIP
GRAVURE; 50% to 150% OF LINESPEED
OFFSET GRAVURE
BACKING; LINESPEED
BACKING/OFFSET =3/8 NIP
OFFSET; 95% to 105% OF LINESPEED
Undercut Required
OFFSET/GRAVURE = 3/8 NIP
GRAVURE; 10% to 25% OF LINESPEED
-
7/23/2019 3-coating
15/17
SMOOTH ROLL
BACKING; LINESPEED
NOUndercut Required
BACKING/PICKUP = VARY NIP
PICKUP;20% to 150% LINESPEED
COAT WEIGHT
NIP WIDTH & ROLL SPEEDCoat weight control is dependent upon the relationship of
linespeed vs. nip width and pickup roll speed
By increasing pickup roll speed the coat weight increases
By decreasing the pickup roll footprint the coat weight
increases
Other coat weight variables
coating solids
coating viscosity
Transfer Roll Coater
Roll vs. Speed
Roll speed
Coatweight
1/2" nip
3/8" nip
3/4" nip
CHECKING NIP
IMPRESSIONS
STEEL ROLL
LOAD
RUBBERCOVEREDROLL
FOOTPRINT
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7/23/2019 3-coating
16/17
Coat Weight Curves
Gravure Volume
Coating Solids
Roll Speed
Coating Viscosity
GSM
150%50% 100%
Gravure Speed
Reverse
Gravure
GSM
95% 100% 105%
Gravure Speed
Forward
Gravure
10% 60% 100%
Gravure Speed
GSM
Offset
Gravure
10% 100%
Pick-up Speed
GSM
Smooth
Transfer
Factors That Affect Coat Weight
Nip Width
COAT WEIGHT STABILITYEffects of speed on coatweight
Differential Offset Gravure -STABLE
Direct/Reverse Gravure -STABLE
Smooth Roll -UNSTABLE
GSM
Line Speed
Gravure
Smooth Roll
Yesesoes
bility to Coat Foil
bility to Coat Foil
Yesesoes
bility to Coat
bility to Coat
Printed Film
rinted Film
Noeseses
equires Undercut
equires Undercut
Rubber Roll
ubber Roll
Noeseses
table at ll Line
table at ll Line
Speeds
peeds
Yesesesesbility to Coatbility to Coat
Film
ilm
Noeseses
bility to Coat
bility to Coat
Paper
aper
Yeseseso
bility to djust
bility to djust
Coat Weight
oat Weight
Smooth
mooth
Roll
oll
Offset
ffset
Gravure
ravure
Reverse
everse
Gravure
ravure
Direct
irect
Gravure
ravure
Coater
oater
Selection
election
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7/23/2019 3-coating
17/17
Thank You
PRESENTED BY
Lee A. OstnessProduct ManagerCoating & Drying Systems
Black Clawson Converting [email protected]
Please remember to t urn
in you r evaluation sheet...
